ESAB Aristo Retrofit I/O Interface Universal 255 User manual

Brand: ESAB

Model: Aristo Retrofit I/O Interface Universal 255

Category: Welding System

Type: User manual

This manual is also suitable for

Aristo® Retrofit I/O Interface Universal 255

ESAB Aristo Retrofit I/O Interface Universal 255 is a device that checks and converts CAN bus signals from a power source to a welding robot. It's compatible with CAN bus-controlled power sources like Mig 4000i or Mig 5000i with U82 I/O. It converts analog and digital signals to field bus communication (CAN) and vice versa.

AH 0736c

Valid for serial no. 222-xxx-xxxx0461 314 001 GB 20130531

Aristo

Retrofit I/O Interface

Universal 255

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

SPARE PARTS LIST 20..................................................

ASSEMBLY INSTRUCTIONS 18...........................................

1 SAFETY 4...........................................................

2 INTRODUCTION 6...................................................

2.1 Equipment 6................................................................

3 TECHNICAL DATA 6.................................................

4 INSTALLATION 6....................................................

4.1 Location 7..................................................................

4.2 Connection instructions 8.....................................................

Others 8.........................................................................

5 OPERATION 9.......................................................

5.1 Connections and control devices 9............................................

6 MAINTENANCE 10....................................................

6.1 Inspection and cleaning 10....................................................

7 FAULT TRACING 10..................................................

8 ORDERING SPARE PARTS 10.........................................

9 CONNECTION & FUNCTION DESCRIPTION OF I/O SIGNALS 11..........

9.1 Connection table for I/O signals on robot side 11.................................

9.2 Input data I/O signals from robot controller to welding equipment 12.................

9.3 Output data I/O signals from the welding equipment to the robot controller 14........

DIAGRAM 16............................................................

ORDER NUMBER 18.....................................................

ACCESSORIES 19.......................................................

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1 SAFETY

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or

near the equipment observes all the relevant safety precautions. Safety precautions must meet the

requirements that apply to this type of equipment. The following recommendations should be

observed in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the

equipment. Incorrect operation of the equipment may lead to hazardous situations which can result

in injury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

S its operation

S location of emergency stops

S its function

S relevant safety precautions

S welding and cutting

2. The operator must ensure that:

S no unauthorised person is stationed within the working area of the equipment when it is

started up.

S no-one is unprotected when the arc is struck

3. The workplace must:

S be suitable for the purpose

S be free from drafts

4. Personal safety equipment

S Always wear recommended personal safety equipment, such as safety glasses, flame-proof

clothing, safety gloves.

S Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions

S Make sure the return cable is connected securely.

S Work on high voltage equipment may only be carried out by a qualified electrician.

S Appropriate fire extinquishing equipment must be clearly marked and close at hand.

S Lubrication and maintenance must not be carried out on the equipment during operation.

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WARNING

Read and understand the instruction manual before installing or operating.

Arc welding and cutting can be injurious to yourself and others. Take precautions when welding and

cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard

data.

ELECTRIC SHOCK - Can kill

S Install and earth the unit in accordance with applicable standards.

S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

S Insulate yourself from earth and the workpiece.

S Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health

S Keep your head out of the fumes.

S Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone

and the general area.

ARC RAYS - Can injure eyes and burn skin.

S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

S Protect bystanders with suitable screens or curtains.

FIRE HAZARD

S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE - Excessive noise can damage hearing

S Protect your ears. Use earmuffs or other hearing protection.

S Warn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

CAUTION

Read and understand the instruction manual before

installing or operating.

CAUTION

This product is solely intended for arc welding.

Dispose of electronic equipment at the recycling facility!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic

Equipment and its implementation in accordance with national law, electrical and/or

electronic equipment that has reached the end of its life must be disposed of at a

recycling facility.

As the person responsible for the equipment, it is your responsibility to obtain

information on approved collection stations.

For further information contact the nearest ESAB dealer.

ESAB can provide you with all necessary welding protection and accessories.

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2 INTRODUCTION

Retrofit I/O Interface Universal 255 checks and converts the CAN bus signals from

the power source to the welding robot and is used for CAN bus controlled power

sources, such as Mig 4000i or Mig 5000i with U8

I/O.

Retrofit I/O Interface Universal 255 converts analogue and digital signals to field

bus communication (CAN) and from field bus signals to digital and analogue signals.

2.1 Equipment

Retrofit I/O Interface Universal 255 is supplied with an instruction manual, control

cable and 48-pol sleeve plug and 0 cable that connects between interface and robot

cabinet.

ESAB can provide you with all necessary welding protection and accessories.

3 TECHNICAL DATA

Retrofit I/O Interface Universal 255

Mains voltage (from robot) 24 V DC

Fuse 1 A

Robot connection 48 pin connection socket

Weight 6.1 kg

Dimensions (l x w x h) 365 x 351 x 110 mm

Enclosure class IP23

Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid

objects or water. Equipment marked IP23 is designed for indoor and outdoor use.

4 INSTALLATION

The installation must be carried out by a professional.

CAUTION

This product is intended for industrial use. In a domestic environment this product may

cause radio interference. It is the user's responsibility to take adequate precautions.

WARNING

When welding in an environment with increased electrical danger, only power

sources intended for this environment may be used. These power sources are

marked with the symbol

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4.1 Location

Retrofit I/O Interface Universal 255 is installed above the power source. Remove

the rubber mat (C) on the power source and then slide the flange of the interface box

(A) into the side profiles (B) of the power source, see the illustration below.

IMPORTANT! Screw the 3 screws into place on the front of the interface box, tighten

sufficiently hard that electrical connection is made. Check that an electrical

connection has been established.

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4.2 Connection instructions

Complete descriptions of the power source / wire feed unit are available in separate

instruction manuals.

1 Connection cables from welding power

source to the wire feed unit.

4 Aristo U8

2 CAN bus connection (12 pole Burndy)

from the welding power source to I/O

Interface.

5 Connection between power source unit

and the robot cabinet (potential cable 0V)

3 Control cable between Retrofit I/O

Interface Universal 255 and Robot control

ler

Others

0-cable 6 mm

S The 0-cable 6 mm

between the power source and the robot cabin is delivered in lengths of

15 m and must be cut to the length required at installation.

Start up time

S The start up time of the Interface box when current/power is activated can be delayed by up

to 1 minute.

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5 OPERATION

General safety regulations for handling the equipment can be found on

page 4. Read through before you start using the equipment!

5.1 Connections and control devices

1 Indicator lamp (WHITE), power supply

from robot.

3 Fuse / 1A 24 VDC from robot

2 Connection for signals to/from the robot's

welding gun (48-pol pin socket connector)

4 Connection for torch cleaning station

5 Connection for operating cable from power

source (12-pin CAN bus)

Retrofit I/O Interface Universal 255 is connected to the robot cabinet and the power

source.

The rating plate is located on the

rear side of the Interface box.

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6 MAINTENANCE

Regular maintenance is important for safe, reliable operation.

Only those persons who have appropriate electrical knowledge (authorized

personnel) may remove the safety plates.

CAUTION

All guarantee undertakings from the supplier cease to apply if the customer attempts any

work to rectify any faults in the product during the guarantee period.

6.1 Inspection and cleaning

Regularly check that the interface box has electrical connection with the power

source and that the connections are correctly connected and not faulty.

7 FAULT TRACING

S Has the indicator lamp (white) on the front gone out?

Check that the fuse is intact.

S Ensure that the wiring is correctly located in its connectors.

Complete descriptions of the power source, wire feed unit and control panel are available in separate

instruction manuals.

8 ORDERING SPARE PARTS

Repair and electrical work should be performed by an authorised ESAB service

technician. Use only ESAB original spare and wear parts.

Retrofit I/O Interface Universal 255 is designed and tested in accordance with the inter

national and European standards 60974-1 and 60974-10. It is the obligation of the ser

vice unit which has carried out the service or repair work to make sure that the product

still conforms to the said standard.

Spare parts may be ordered through your nearest ESAB dealer, see the last page of

this publication.

* * *

NOTE! 9. CONNECTION AND FUNCTION DESCRIPTION OF I/O SIGNALS

is only available in English and is primarily meant for the integrator and installation of

the Interface box on page 11.

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9 CONNECTION & FUNCTION DESCRIPTION OF I/O SIGNALS

The Retrofit I/O Interface Universal is the interface between the welding robot and the

welding equipment. The Retrofit I/O Interface Universal converts the robot’s I/O signals to

field bus signals to the welding equipment. The Retrofit I/O Interface Universal also

converts the field bus signals from the welding equipment to I/O signals to the welding

robot.

9.1 Connection table for I/O signals on robot side

Connection Cable number

Robot side

I/O Signals

H 8 Weld on

J 9 Gas purge

K 10 Inching wire

L 11 Reverse inching wire

M 12 Air purge

N 13 0V = Quick stop

P 14 analogue active

R 15 Touch sense

S 16 Memory 1

T 17 Memory 2

U 18 Memory 4

V 19 Memory 8

X 21 Memory 16

W 20 Memory 32

Y 22 Memory 64

Z 23 Memory 128

E 5 Voltage reference

F 6 Wirefeed reference

G 7 0V reference to robot

a 24 Arc acknow.

b 25 Touch sense resp.

c 26 0V = Machine error

d 27 Collision detect

e 28 Weld busy

f 29 Remote active

A 1 24V supply from robot

B 2 0V supply from robot

Shield Shield Ground

v 30 G-Stop

u 31 G-Stop

p 32 G-Stop

q 33 G-Stop

g 34 Lubrication

h 35 Lubrication cleaning

i 36 Lubrication finish

Input

Output

Power

General

Torch

Analogue

supply

Equipment

cleaning

Input

stop

Equipment

Welding

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9.2 Input data I/O signals from robot controller to welding

equipment

Weld ON (Cable no 8)

The signal starts the welding process, but before the welding process starts the

quick stop and stop signals are checked to ensure that they are not active.

Quick stop (Cable no 13)

The signal stops the equipment if it is active in the welding process, it carries out a

normal stop without crater filling. The function is used when a quick stop (low signal

0V) is required but it gives a normal burnback time to prevent the wire sticking in the

weld pool. The signal also blocks the start command.

Wire inching (Cable no 10)

Used when one wants to feed wire without welding voltage.

The signal starts the wire feed without the welding voltage being activated. The wire

feed unit is ramping up the wire feed speed. If the signal is active during the welding

process, the command is ignored.

If both welding and wire inching are activated at the same time the equipment will

ignore the wire inching command and start the welding process.

Gas purge (Cable no 9)

Gas flushing is used when measuring the gas flow or to flush any air or moisture

from the gas hoses before welding starts. Gas flushing is carried out without voltage

or wire feed occurring.

Welding start always activates the gas valve even if the manual gas command is

given. In the same way the gas valve for gas post flow is always closed if it is not

closed already.

Gas flushing operates parallel to the gas pre−flow and gas post−flow functions. To

control the welding gas from the robot, set the gas pre−flow to minimum and the gas

post−flow to maximum, and then control the welding gas using the gas flushing

functions.

Air purge (Cable no 12)

The signal controls the valve for air cleaning welding spatter.

Touch sense (Cable no 15)

This command is used by the robot to sense where the wire is.

When the function is active, the power source will give out current limited, idle

voltage to see if the wire is in contact with the workpiece. On contact, the output

signal ”Touch sense response” is activated.

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Analogue Active (Not availabe for the moment)

The signal is used to switch between the analogue and digital remote modes.

Analogue Active allows analogue control of the welding parameters, voltage, arc

voltage and the wire feed speed.

If the welding method SuperPulse is to be used, the ”analogue active” signal must be

deactivated.

When the analogue method is activated the power source will not use the preset

values for wire feed speed and voltage when new welding data is selected. When

”analogue active” is activated the robot controls arc voltage and wire feed speed

using analogue signals.

With the analogue active signal deactivated, welding data is exchanged with preset

welding data such as voltage, wire feed speed to fixed set welding parameters.

The pre−programmed welding data (schedules) is requested from the control box

welding data memory.

Welding data (Memory) (Cable 16-23)

With the signals memory 1, 2, 4, 8, 15, 32, 64, 128 one accesses saved welding data

(schedules) in U8

I/O.

The binary coded combinations of these signals can be used to recall the memories

1−255 in the U8

I/O memory bank.

A complete set of welding data includes all settings that can be made in U8

I/O, see

the instruction manual for U8

Voltage reference (Cable no 5 - Not available at the moment)

This signal is used by the robot for analogue control of the welding voltage if

analogue active is selected. It stretches from 0−10V and corresponds to welding

voltage socket as follows.

0V reference gives a deviation on the selected arc voltage of −10V

10V reference gives a deviation on the selected arc voltage of +10V

If the machine is in non−synergy mode, the equipment will use the appreciated

value.

0V reference gives arc voltage 8V

10V reference gives arc voltage 60V

Wire feed speed reference signal (Cable no 6 - Not available at the moment)

The signal is used by the robot to make analogue adjustments to the wire feed

speed. The internal solution is 0.1 m/min.

Input voltage

0 V Mini. value for wire feed (normally 0.8 m/min) (RoboFeed)

10 V Max. value for wire feed (normally 30 m /min)

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9.3 Output data I/O signals from the welding equipment to the

robot controller

Arc acknowledge (Cable no 25)

The signal is activated after established welding start if the voltage and current

strength lie within weldable limits. The signal disappears if welding cannot be

established.

The criterion for establishing a welding arc is that the process control has passed the

start− procedure, which means that only a short circuit is not sufficient to meet the

criteria. Normal delay from the first contact, which is acknowledged by the welding

arc (wire feed time for this after the first contact is established ) is in the range of 2 to

20 ms. If there is a poor start to the welding arc the ”Arc acknowledge” is further

delayed.

Touch sense response (Cable no 26)

This signal indicates contact in the welding circuit, i.e. that the wire is in contact with

the workpiece. To obtain ”touch sense response” the ”touch sense” input signal must

be activated.

Collision detect (Cable no 26)

The signal comes via the internal CAN bus from the feeding mechanism (RoboFeed).

The signal indicates that the robot’s breaker has activated. The interface activates a

relay which breaks two safety loops from the robot, at which the robot orders a quick

stop of both robot and the welding equipment.

The output is high when the welding gun breaker is tripped (the signal is sent to the

robot).

Machine error (Cable no 27)

The signal is low (0V) when an error has been detected in the welding equipment.

Weld busy (Cable no 28)

This signal indicates when the welding equipment is occupied with welding. The

signal can be configurated in the U82 I/O configuration menu.

Remote active (Cable no 29)

Remote active is activated when remote is chosen in U8

General stop (Cable no 30-33)

Can be used as an electrical stop, to stop the servo motors on the robot, when

collision detect signal is low (0V).

Diagram

Com 0V

Wire 0-10V

Voltage 0-10V

CAN HIGH

CAN LOW

24VR

0VR

24VR

0VR

Reserve

Remote Active

Weld Busy

Filter board 1

Digital output from

equipment

Bus

resistor

External General Stop

Torch cleaner

XS04

24VR

0VR

C B A

HL1

024023

026025

414

154

KL3062

101

603

102

505

103

401

XP01

1 2

B K L E G

XS03

h g G F E

1 2 3

53 17

KL9010

Power source

XS01

B K L E G

XP03

i h g v u p q

v u p q

224 223 221

222114

201

022

G F E

33323130

567

343536

KL2134:2

14 583276

612

711

815

315

613

712

415

615

614

714

713

1 2 3 4

616

715

Analog input

to equipment

Interface Box

Not available at the moment

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24VR

0VR

24VR

0VR

Collision Detect

Machine Error=0V

Tourch Sense R.

Arc Acknowledge

Memory 8

Memory 4

Memory 2

Memory 1

Wire Feeder

Reserve

Tourche Sense

Reserv

Analog Active

Quick Stop

Air Purque

Reverse Wire

Inching

Gas Purge

Weld On

CAN LOW

CAN HIGH

Memory 128

Memory 64

Memory 32

Memory 16

Reserve

Filter board 2

Filter board 1

Digital input to

equipment

Digital input to

equipment

Digital input to

equipment

Digital output from

equipment

Robot

AP1

KL2134:1

104

304

105205

106

1001

KL1408:2

001

1808

002

1704

003

1607

004

1503

008

1101

KL1408:1

111

011807

012

703

014

502

015405

016

301

BK5151

017

200

218

FU1

018

124

c b a V U T S R N M K J H B A

123

18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3

2 1

4 5 6

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

2 1

12 56374812 56374814 583276

4 3 1

Interface Box

7 2 3

N M K J H B Ac b a V U T S R

16171819

242526

606

904

13 12 10 9

010

013

005

1405

220302

12 563748

KL1408:3

AP1

AP2

4 3 2 1

Z Y X

212223 20

1504

1603

1701

1801

1806

1702

1605

1501

202

203

Shield

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Retrofit I/O Interface Universal 255

Order number

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Ordering no. Denomination Notes

0461 090 884 Retrofit I/O Interface Universal 255 Includes the Control cables, see on

page 18 and a Instruction manual.

0461 314 001 Instruction manual Retrofit I/O Interface Universal 255

0459 839 091 Spare parts list Retrofit I/O Interface Universal 255

Retrofit I/O Interface Universal 255

Accessories

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Aristo

[

I/O ........................... 0460 820 883

Rebuilding kit Incl. Adapter (12 pole to 10 pole) .

Mig 4002, 5002 and 6502

0461 322 880

Extension cable (U8

, 7,5 m) ................. 0460 877 891

Control cable

Retrofit I/O to power source (1,7 m) ........... 0461 319 880 *

Control cable (7,5 m, 48-pole) ................. 0461 321 880

* Included in 0461 090 884 Retrofit I/O Interface Universal 255

www.esab.com

ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H

Vienna-Liesing

Tel: +43 1 888 25 11

Fax: +43 1 888 25 11 85

BELGIUM

S.A. ESAB N.V.

Heist-op-den-Berg

Tel: +32 70 233 075

Fax: +32 15 257 944

BULGARIA

ESAB Kft Representative Office

Sofia

Tel/Fax: +359 2 974 42 88

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o.

Vamberk

Tel: +420 2 819 40 885

Fax: +420 2 819 40 120

DENMARK

Aktieselskabet ESAB

Herlev

Tel: +45 36 30 01 11

Fax: +45 36 30 40 03

FINLAND

ESAB Oy

Helsinki

Tel: +358 9 547 761

Fax: +358 9 547 77 71

FRANCE

ESAB France S.A.

Cergy Pontoise

Tel: +33 1 30 75 55 00

Fax: +33 1 30 75 55 24

GERMANY

ESAB GmbH

Solingen

Tel: +49 212 298 0

Fax: +49 212 298 218

GREAT BRITAIN

ESAB Group (UK) Ltd

Waltham Cross

Tel: +44 1992 76 85 15

Fax: +44 1992 71 58 03

ESAB Automation Ltd

Andover

Tel: +44 1264 33 22 33

Fax: +44 1264 33 20 74

HUNGARY

ESAB Kft

Budapest

Tel: +36 1 20 44 182

Fax: +36 1 20 44 186

ITALY

ESAB Saldatura S.p.A.

Bareggio (Mi)

Tel: +39 02 97 96 8.1

Fax: +39 02 97 96 87 01

THE NETHERLANDS

ESAB Nederland B.V.

Amersfoort

Tel: +31 33 422 35 55

Fax: +31 33 422 35 44

NORWAY

AS ESAB

Larvik

Tel: +47 33 12 10 00

Fax: +47 33 11 52 03

POLAND

ESAB Sp.zo.o.

Katowice

Tel: +48 32 351 11 00

Fax: +48 32 351 11 20

PORTUGAL

ESAB Lda

Lisbon

Tel: +351 8 310 960

Fax: +351 1 859 1277

ROMANIA

ESAB Romania Trading SRL

Bucharest

Tel: +40 316 900 600

Fax: +40 316 900 601

RUSSIA

LLC ESAB

Moscow

Tel: +7 (495) 663 20 08

Fax: +7 (495) 663 20 09

SLOVAKIA

ESAB Slovakia s.r.o.

Bratislava

Tel: +421 7 44 88 24 26

Fax: +421 7 44 88 87 41

SPAIN

ESAB Ibérica S.A.

Alcalá de Henares (MADRID)

Tel: +34 91 878 3600

Fax: +34 91 802 3461

SWEDEN

ESAB Sverige AB

Gothenburg

Tel: +46 31 50 95 00

Fax: +46 31 50 92 22

ESAB international AB

Gothenburg

Tel: +46 31 50 90 00

Fax: +46 31 50 93 60

SWITZERLAND

ESAB AG

Dietikon

Tel: +41 1 741 25 25

Fax: +41 1 740 30 55

UKRAINE

ESAB Ukraine LLC

Kiev

Tel: +38 (044) 501 23 24

Fax: +38 (044) 575 21 88

North and South America

ARGENTINA

CONARCO

Buenos Aires

Tel: +54 11 4 753 4039

Fax: +54 11 4 753 6313

BRAZIL

ESAB S.A.

Contagem-MG

Tel: +55 31 2191 4333

Fax: +55 31 2191 4440

CANADA

ESAB Group Canada Inc.

Missisauga, Ontario

Tel: +1 905 670 02 20

Fax: +1 905 670 48 79

MEXICO

ESAB Mexico S.A.

Monterrey

Tel: +52 8 350 5959

Fax: +52 8 350 7554

USA

ESAB Welding & Cutting Products

Florence, SC

Tel: +1 843 669 44 11

Fax: +1 843 664 57 48

Asia/Pacific

AUSTRALIA

ESAB South Pacific

Archerfield BC QLD 4108

Tel: +61 1300 372 228

Fax: +61 7 3711 2328

CHINA

Shanghai ESAB A/P

Shanghai

Tel: +86 21 2326 3000

Fax: +86 21 6566 6622

INDIA

ESAB India Ltd

Calcutta

Tel: +91 33 478 45 17

Fax: +91 33 468 18 80

INDONESIA

P.T. ESABindo Pratama

Jakarta

Tel: +62 21 460 0188

Fax: +62 21 461 2929

JAPAN

ESAB Japan

Tokyo

Tel: +81 45 670 7073

Fax: +81 45 670 7001

MALAYSIA

ESAB (Malaysia) Snd Bhd

USJ

Tel: +603 8023 7835

Fax: +603 8023 0225

SINGAPORE

ESAB Asia/Pacific Pte Ltd

Singapore

Tel: +65 6861 43 22

Fax: +65 6861 31 95

SOUTH KOREA

ESAB SeAH Corporation

Kyungnam

Tel: +82 55 269 8170

Fax: +82 55 289 8864

UNITED ARAB EMIRATES

ESAB Middle East FZE

Dubai

Tel: +971 4 887 21 11

Fax: +971 4 887 22 63

Africa

EGYPT

ESAB Egypt

Dokki-Cairo

Tel: +20 2 390 96 69

Fax: +20 2 393 32 13

SOUTH AFRICA

ESAB Africa Welding & Cutting Ltd

Durbanvill 7570 - Cape Town

Tel: +27 (0)21 975 8924

Distributors

For addresses and phone

numbers to our distributors in

other countries, please visit our

home page

www.esab.com

ESAB Aristo Retrofit I/O Interface Universal 255 User manual

Brand: ESAB

Model: Aristo Retrofit I/O Interface Universal 255

Category: Welding System

Type: User manual

This manual is also suitable for

Aristo® Retrofit I/O Interface Universal 255

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